Integrated Shielding Foil for Flexible Cable Noise Suppression
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Solution Overview
Problem
Existing communication cables with magnetic material powder dispersed in organic polymers for noise shielding face inefficiencies due to gaps between layers, which hinder effective noise shielding.
Innovation Solution
A shielding foil comprising a laminated structure of a non-magnetic metal foil with a thickness of 5 μm to 12 μm and a magnetic layer made of an oxide magnetic substance with a thickness of 0.05 μm to 6 μm, integrated to prevent gaps and enhance noise shielding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If powder of magnetic material is dispersed in organic polymer to form noise shielding layer, then ease of manufacture is improved, but noise shielding ability deteriorates due to gaps between particles and layers
Solution Approach 1:
The patent combines the magnetic material layer and metal foil layer into a single integrated shielding foil structure, eliminating gaps between separate layers. This merging approach maintains the manufacturing simplicity of using magnetic powder in polymer while removing the interface gaps that cause noise shielding degradation.
Solution Approach 2:
The invention creates a composite shielding foil consisting of magnetic material dispersed in organic polymer combined with metal foil in an integrated laminated structure. This composite approach leverages the advantages of both materials while eliminating the gaps that occur when they are used as separate laminated layers.
2Ease of operation
If metal foil with thickness less than 5 μm is used to improve flexibility, then ease of operation is improved, but manufacturing precision deteriorates due to difficulty in integral lamination
Solution Approach 1:
The patent specifies a minimum thickness of 5 μm for the metal foil to ensure it can be integrally laminated with the magnetic material layer. This parameter change ensures that the metal foil is thick enough for reliable manufacturing while still maintaining sufficient flexibility for practical applications.
3Manufacturing precision
If metal foil with thickness more than 12 μm is used to improve manufacturing precision, then manufacturing precision is improved, but ease of operation deteriorates due to reduced flexibility
Solution Approach 1:
The patent sets the metal foil thickness upper limit at 12 μm to maintain adequate flexibility. This parameter constraint ensures that while the foil is thick enough for reliable integral lamination and manufacturing precision, it remains flexible enough for ease of operation and installation.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The integrated shielding foil effectively suppresses noise shielding ability degradation from gaps, maintaining high noise shielding properties even after bending, while ensuring high flexibility and productivity.
Implementation Method 1
a magnetic layer with a thickness of 0.05 μm or more and 6 μm or less made of an oxide magnetic substance
Implementation Method 2
both the metal foil and the magnetic layer contribute to noise shielding
Implementation Method 3
a metal foil with a thickness of 5 μm or more and 12 μm or less made of a non-magnetic metal
Data Source
AI summary
A shielding foil 10 includes a metal foil 12 with a thickness of 5 μm or more and 12 μm or less made of a non-magnetic metal, and a magnetic layer 13 with a thickness of 0.05 μm or more and 6 μm or less made of an oxide magnetic substance, the metal foil 12 and the magnetic layer 13 being integrally laminated. A communication cable includes a conductor, an insulating layer covering the outer circumference of the conductor, and the shielding foil 10 that surrounds the outside of the insulating layer.